Solar Charge Controller CML05-2, CML08-2
Contents
1. during the day Battery has low capacity Change battery Remove faulty connec a Glad cs tion reverse polarity wrong polarity Remove reverse polarity Battery wrong polarity Battery is connected Permanent with reverse polarity sound General Safety and Usage Recommendations Intended Use The charge controller is intended exclusively for use in photovoltaic systems with 12 V or 24 V nominal voltage and in conjunction with vented or sealed VRLA lead acid batteries only Safety Recommendations Batteries store a large amount of energy Never short circuit a battery under all circumstances We recommend connecting a fuse slow acting type according to the nominal controller current directly to the battery terminal Batteries can produce flammable gases Avoid making sparks using fire or any naked flame Make sure that the battery room is ventilated Avoid touching or short circuiting wires or terminals Be aware that the voltages on specific terminals or wires can be up to double the battery voltage Use isolated tools stand on dry ground and keep your hands dry Keep children away from batteries and the charge controller Please observe the safety recommendations of the battery manufacturer If in doubt consult your dealer or installer Liability Exclusion The manufacturer shall not be liable for damages especially on the battery caused by use other than as intended or as mentioned in this manual or i2. not have an electric connection to the car body otherwise the Low Voltage Disconnect and electronic fuse functions of the controller are short circuited Starting up the Controller Self Test As soon as the controller is supplied with power either from the battery or the solar array it starts a self test routine Then the display changes to normal operation System Voltage The controller adjusts itself automatically to 12 V or 24 V system voltage As soon as the voltage at the time of start up exceeds 20 0 V the controller implies a 24 V system If the battery voltage is not within the normal operation range ca 12 to 15 5 V or ca 24 to 31 V at start up a status display according to the section ERROR DESCRIP TION occurs Battery Type The controller is preset to operate with lead acid batteries with liquid electrolyte If you intend to use a lead acid battery with solid electrolyte gel type or fleece type you can adjust the charging characteristics see Settings The equalization charge is deactivated then In case of any doubts consult your dealer Recommendations for Use The controller warms up during normal operation The controller does not need any maintenance or service Remove dust with a dry tissue It is important that the battery gets fully charged frequently at least monthly Other wise the battery will be permanently damaged A battery can
3. only be fully charged if not too much energy is drawn during charging Keep that in mind especially if you install additional loads Display Functions The controller is equipped with 5 LEDs and an acoustic warming signal Charge display State of charge display Load status display wey TOR 00000 In normal operation the controller shows the state of charge of the battery and the charge from the solar panels Any change of the state of charge SOC to a lower status is additionally signaled acoustically Charge display T l a T l Ue 20 oe Eo i 6 ie Solar array supplies electricity Solar array does not supply electricity State of charge display gt 75 25 5 lt 25 The percentage corresponds to the available energy until Low Voltage Disconnect in relation to a fully charged battery Acoustic signals flashes lt 10 A change in the state of charge SOC to a lower status is indicated by an acoustic signal 0 eo gt 09 gt a ee cr So A E Ix x 3x A E 5x Z040 The loads are disconnected approx minute after a series of 25 signals Load status display In case of deep discharge or overload short circuit of load the load output is switched off This is indicated by 70 FOR 7O03 Normal operation Low voltage disconnect Overload or Short circuit of load Solar Charge Controller CMLO5 2 CMLO8 2 CMLI0 2 CMLI5 2 CML20 User Manual English Page 2 Low Voltage D
4. Solar Charge Controller CMLO5 2 CMLO8 2 CMLI0 2 CMLI5 2 CML20 User Manual English Page Dear Client Thank you very much for buying a Phocos product With your new CML controller you own a state of the art device which was developed according to the latest available technical standards It comes with a number of outstanding features like Clear readable display of the state of charge Acoustic signal when the state of charge changes Low voltage disconnect regulated by state of charge or voltage 6 mm connector clamps Complete electronic protection This manual gives important recommendations for installing using and programming as well as remedies in case of problems with the controller Read it carefully in your own interest and mind the safety and usage recommendations at the end of this manual Description of Functions The charge controller protects the battery from being overcharged by the solar array and from being deep discharged by the loads The charging characteristics include several stages which include automatic adaptation to the ambient tempera ture The charge controller adjusts itself automatically to 12V or 24V system voltage The charge controller has a number of safety and display functions Mounting and Connecting The controller is intended for indoor use only Protect it from direct sunlight and place it in a dry environment Never install it in humid rooms like bathrooms The con
5. cturer We strongly recommend connecting a fuse directly to the battery to protect any short circuit at the battery wiring The fuse must take the charge controller nominal current CMLOS 20A CMLO8 20A CMLI0 30A CMLI5 30A CML20 40A Connect the wires leading to the solar array with correct polarity To avoid any voltage on the wires first connect the controller then the solar array Mind the recommended wire size CMLO5 min 2 5 mm CLMO8 min 4 mm CMLI0 min 6 mm CMLI5 CML20 min 10 mm REMARK Place positive and negative wire close to each other to minimize electro magnetic effects REMARK Solar panels provide voltage as soon as exposed to sun light Mind the solar panel manufacturer s recommendations in any case Connect the wires leading to the loads with correct polarity To avoid any voltage on the wires first connect the wire to the load then to the controller Mind the recommended wire size CMLOS min 2 5 mm CLMO8 min 4 mm CMLI0 min 6 mm CMLI5 CML20 min 10 mm phocos Grounding the Solar System Be aware that the positive terminals of the CML controller are connected internally and therefore have the same electrical potential If any grounding is required always do this on the positive wires LE ETIT LAITI ETTE E EA FEREENA L ERIRE IDTE ED ERIRE REMARK If the device is used in a vehicle which has the battery negative on the chassis loads connected to the controller must
6. f the recommendations of the battery manufacturer are neglected The manufacturer shall not be liable if there has been service or repair carried out by any unauthorized person unusual use wrong installation or bad system design Technical Data Equalization voltage 14 8 29 6 V 25 C 2 h Low Voltage Disconnect 1 4 1 1 9 22 8 23 8 V controlled by state of charge Function 1 0 22 0 V controlled by voltage Load reconnect voltage 12 8 25 6 V Temperature compensa 4 mV cell K tion Max solar panel current 5 8 10 15 20 A according to model number 50 C 5 8 10 15 20 A according to model number 50 C Dimensions 80 x 100 x 32 mm wxh xd Max wire size 16 mm AWG 6 Ambient temperature 25 to 50 C range Case protection IP 20 C Max load current Subject to change without notice Version CMLO41214 Made in one of the following countries Germany China Bolivia India Phocos AG Germany www phocos com
7. isconnect Function LVD The controller has 2 different modes to protect the battery from being deeply discharged State of charge controlled Disconnect at 1 4 V at nominal load current up to 1 9 V at no load current Normal operation mode for good battery protection 2 Voltage controlled Disconnect at 1 0 V fixed setting Appropriate if bypass loads draw current directly from the battery The controller is preset to Mode from the factory Changing the mode setting is described below In case of doubts which mode to choose consult your dealer because this has to be evaluated depending on the battery used The controller can be configured for special operation For this purpose open the cover of the controller by removing the screws on the back side ARNING The controller should not be opened while connected and in opera ion When the controller is opened there are 3 jumpers on the electronic board For changing put the jumper either on both contact pins or only on one contact pin I Closed jumper Open jumper GELI r disconnect open electrolyte trolled GEL VRLA battery Jumper open state of Jumper closed charge controlled Alarm on Setting jumper closed Factory setting Jumper open liquid electro lyte After completing the setting replace the cover and tighten it with the screws Safety Features The controller is protected against wrong installation or use Pany oes Un
8. restricted Normal operation Unrestricted ith correct polarity pate CONNECTS i jpesnieted Nestled ACau i iasineied ith wrong polarity ic Warming es not at 24V i Load output is battery is connected protected Loads system voltage Acoustic Warning might be damaged Unrestricted Unrestricted CAUTION Battery Unrestricted must be protected by fuse Overcurrent No protection Controller switches off load terminal hermal overload No protection otal switches off load terminal No connection Unrestricted Unrestricted Unrestricted everse Curent Unresticted fp off load terminal off load terminal off load terminal ARNING The combination of different error conditions may cause damage to he controller Always remove the error before you continue connecting the controller Reverse polarity Error Description Display Load will reconnect as soon as battery Is recharged Switch off all loads Remove short circuit Controller will switch on load automatically after max minute lt Battery is low See Overcurrent Short 3 x circuit of loads Loads are not supplied Check if other sources overcharge the battery If not controller is damaged Battery voltage too high gt 15 5 31 0 V Battery wires or battery fuse damaged battery has high resistance Check battery wires fuses and battery Battery is empty after a short time Battery is not being charged
9. troller measures the ambient temperature to determine the charging voltage Controller and battery must be installed in the same room The controller warms up during operation and should therefore be installed on a non flammable surface only REMARK Connect the controller by following the steps described below to avoid installation faults Mount the controller to the wall with screws that fit to the wall material Use screws with 4 mm shaft and max 8 mm head diameter no counter sunk Mind that the screws have to carry also the force applied by the wiring Make sure that the ventilator slits on the sides are unob structed A DIN Rail mounting plate is available as an accessory CX DR2 This allows mount ing the controller on a standard 35mm DIN rail Remove the screws at the backside of the controller and screw the mounting plate with the long fastening screw onto the backside of the controller Connect the wires leading to the battery with correct polarity To avoid any voltage on the wires first connect the controller then the battery Mind the recommended wire length min 30 cm to max approx 100 cm and the wire size CMLOS min 2 5 mm CLMO8 min 4 mm CMLI0 min 6 mm CMLI5 CML20 min 10 mm ARNING If the battery is connected with reverse polarity the load terminals ill also have the wrong polarity Never connect loads during this condition REMARK Mind the recommendations of your battery manufa
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